EP0697419A1 - Catalyseur de polymérisation d'oléfines et procédé de polymérisation d'oléfines - Google Patents

Catalyseur de polymérisation d'oléfines et procédé de polymérisation d'oléfines Download PDF

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EP0697419A1
EP0697419A1 EP95305560A EP95305560A EP0697419A1 EP 0697419 A1 EP0697419 A1 EP 0697419A1 EP 95305560 A EP95305560 A EP 95305560A EP 95305560 A EP95305560 A EP 95305560A EP 0697419 A1 EP0697419 A1 EP 0697419A1
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group
carbon atoms
compound
bis
zirconium dichloride
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EP0697419B2 (fr
EP0697419B1 (fr
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Toshiyuki C/O Mitsui Petrochem. Ind. Ltd Tsutsui
Ken C/O Mitsui Petrochem. Ind. Ltd. Yoshitsugu
Masaaki C/O Mitsui Petrochem. Ind. Ltd. Ohgizawa
Junichi C/O Mitsui Petrochem. Ind. Ltd. Imuta
Tetsuhiro Mitsui Petrochem. Ind. Ltd. Matsumoto
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Mitsui Chemicals Inc
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65912—Component covered by group C08F4/64 containing a transition metal-carbon bond in combination with an organoaluminium compound
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/65916—Component covered by group C08F4/64 containing a transition metal-carbon bond supported on a carrier, e.g. silica, MgCl2, polymer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F4/00—Polymerisation catalysts
    • C08F4/42—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors
    • C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
    • C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
    • C08F4/62—Refractory metals or compounds thereof
    • C08F4/64—Titanium, zirconium, hafnium or compounds thereof
    • C08F4/659—Component covered by group C08F4/64 containing a transition metal-carbon bond
    • C08F4/6592—Component covered by group C08F4/64 containing a transition metal-carbon bond containing at least one cyclopentadienyl ring, condensed or not, e.g. an indenyl or a fluorenyl ring
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
    • Y10S526/904—Monomer polymerized in presence of transition metal containing catalyst at least part of which is supported on a polymer, e.g. prepolymerized catalysts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
    • Y10S526/943—Polymerization with metallocene catalysts

Definitions

  • the present invention relates to olefin polymerization catalysts by the use of which olefin polymers of excellent particle properties can be obtained and to processes for olefin polymerization using said catalysts.
  • Olefin polymerization catalysts comprising transition metal compounds and organometallic compounds have been heretofore known as catalysts for preparing olefin (co)polymers such as ethylene polymer, propylene polymer and ethylene- ⁇ -olefin copolymer.
  • olefin polymerization catalysts comprising transition metal compounds such as zirconocene and organoaluminum oxy-compounds (aluminoxane) are known as catalysts capable of preparing olefin (co)polymers with high polymerization activity.
  • Processes for preparing olefin (co)polymers using such catalysts have been proposed in, for example, Japanese Patent Laid-Open Publications No. 19309/1983, No. 35005/1985, No. 35006/1985, No. 35007/1985 and No. 35008/1985.
  • the present inventors have earnestly studied under such circumstances as mentioned above, and they have found that the properties of a solid catalyst or a prepolymerized catalyst have influence on the properties of the resulting polymer and that the molar ratio of the alkyl group to the aluminum atom in the organoaluminum oxy-compound have influence on the activity of olefin polymerization and the properties of the resulting polymer.
  • a solid catalyst or a prepolymerized catalyst which has a specific bulk density and a specific fluidity index
  • a solid catalyst or a prepolymerized catalyst which comprises an organoaluminum oxy-compound having a specific molar ratio of the alkyl group to the aluminum atom, a fine particle carrier and a transition metal compound and has a specific bulk density and a specific fluidity index, hardly produce a fine-powdery polymer in the olefin polymerization procedure and can prepare an olefin polymer of excellent particle properties.
  • a solid catalyst which comprises an organoaluminum oxy-compound having a specific molar ratio of the alkyl group to the aluminum atom, a fine particle carrier and a specific transition metal compound, has high activity of propylene polymerization, hardly produces the component of low molecular weight and can prepare a polymer of excellent particle properties. Based on these findings, the present invention has been accomplished.
  • the olefin polymerization catalyst according to the present invention is a solid catalyst comprising: a fine particle carrier;
  • the olefin polymerization catalyst according to the present invention is a prepolymerized catalyst comprising: a fine particle carrier;
  • the organoaluminum oxy-compound (B) desirably has a molar ratio of the alkyl group to the aluminum atom (alkyl group/aluminum atom) (hereinafter sometimes referred to as "R/Al ratio") of not less than 1.3 and less than 1.7.
  • the organoaluminum oxy-compound (B) is desirably an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 by bringing an organoaluminum oxy-compound into contact with water and/or an inorganic compound.
  • the organoaluminum oxy-compound (B) is desirably an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 by bringing an organoaluminum oxy-compound having an R/Al ratio of more than 2.1 into contact with water, preferably adsorbed water adsorbed on an inorganic compound, or the organoaluminum oxy-compound (B) is desirably an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 by bringing an organoaluminum oxy-compound having an R/Al ratio of less than 1.7 into contact with an inorganic compound substantially not containing water.
  • the solid catalyst or the prepolymerized catalyst which contains an organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 or contains an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 and has the above-defined bulk density and fluidity index, a fine-powdery polymer is hardly produced in the polymerization procedure and a polymer of excellent particle properties can be obtained.
  • the process for olefin polymerization according to the present invention comprises polymerizing or copolymerizing an olefin in the presence of the olefin polymerization catalyst described above.
  • a fine-powdery polymer is hardly produced in the polymerization procedure and a polymer of excellent particle properties can be obtained. Additionally, the polymer hardly sticks to the wall of the polymerization reactor or the stirrer in the polymerization procedure.
  • the propylene polymerization catalyst according to the present invention comprises: a fine particle carrier
  • transition metal compounds represented by the formula (I) preferred are transition metal compounds represented by the following formulae (Ia), (Ib) and (Ic); wherein M1 is a transition metal atom of Group IVB of the periodic table, R11 is a hydrocarbon group of 1 to 6 carbon atoms, R1, R14, R15 and R16 may be the same as or different from each other, and are each hydrogen, a halogen atom or a hydrocarbon group of 1 to 6 carbon atoms, R13 is hydrogen or an aryl group of 6 to 16 carbon atoms, which may be substituted with a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms or an organosilyl group, X1 and X are each hydrogen, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, an oxygen-containing group or a sulfur-containing group, Y is a divalent hydrocarbon group of 1 to 20 carbon atom
  • the propylene polymerization catalyst of the invention is prepared by using the specific transition metal compound as the transition metal catalyst component and the organoaluminum oxy-compound having a specific R/Al ratio as the organoaluminum compound component, it shows high activity of propylene polymerization, and when it is used, a component of low-molecular weight is hardly produced and the resulting polymer has excellent particle properties.
  • the process for preparing a propylene polymer according to the present invention comprises homopolymerizing propylene or copolymerizing propylene as a major monomer and other olefin than propylene as a minor monomer in the presence of the propylene polymerization catalyst described above.
  • an organoaluminum compound may be used in combination with the propylene polymerization catalyst.
  • a fine-powdery polymer is hardly produced and a polymer having excellent particle properties can be obtained. Further, the polymer hardly sticks to the wall of the polymerization reactor or the stirrer.
  • Fig. 1 is a chart showing one example of a 1H-NMR spectrum of an organoaluminum oxy-compound used in the present invention.
  • Fig. 2 is an explanatory chart of curve fitting by using Lorentz's function.
  • Fig. 3 is an explanatory view of a process for preparing an olefin polymerization catalyst according to the present invention.
  • Fig. 4 is a photomicrograph of a particle structure of a prepolymerized catalyst prepared in Example 1.
  • Fig. 5 is a photomicrograph of a particle structure of a prepolymerized catalyst prepared in Comparative Example 1.
  • the olefin polymerization catalyst, the process for olefin polymerization, the propylene polymerization catalyst and the process for propylene polymerization, according to the present invention, will be described in detail hereinafter.
  • a preferred embodiment of the olefin polymerization catalyst according to the invention is a solid catalyst comprising: a fine particle carrier;
  • Another preferred embodiment of the olefin polymerization catalyst according to the invention is an olefin polymerization catalyst which is a prepolymerized catalyst comprising: a fine particle carrier;
  • the fine particle carrier for forming the olefin polymerization catalyst of the invention is an inorganic or organic compound, and is a granular or particulate solid having a particle diameter of 10 to 300 ⁇ m, preferably 20 to 200 ⁇ m.
  • the inorganic compound is preferably a porous oxide, and examples thereof include SiO2, Al2O3, MgO, ZrO2, TiO2, B2O3, CaO, ZnO, BaO, ThO2 and mixtures thereof such as SiO2-MgO, SiO2-Al2O3, SiO2-TiO2, SiO2-V2O5, SiO2-Cr2O3 and SiO2-TiO2-MgO. Of these, preferred is a compound containing as its major component at least one selected from the group consisting of SiO2 and Al2O3.
  • the above-mentioned inorganic oxides may contain carbonates, sulfates, nitrates and oxides, e.g., Na2CO3, K2CO3, CaCO3, MgCO3, Na2SO4, Al2(SO4)3, BaSO4, KNO3, Mg(NO3)2, Al(NO3)3, Na2O, K2O and Li2O, in small amounts.
  • the properties of the fine particle carrier vary depending on the type thereof and the process for the preparation thereof, but preferably used in the invention is a fine particle carrier having a specific surface area of 50 to 1,000 m/g, preferably 100 to 700 m/g, and a pore volume of 0.3 to 2.5 cm3/g.
  • the fine particle carrier may be used after calcined at a temperature of 100 to 1,000 °C, preferably 150 to 700 °C, if desired.
  • the fine particle carrier desirably has an adsorbed water content of less than 1.0 % by weight, preferably less than 0.5 % by weight, and a surface hydroxyl group content of not less than 1.0 % by weight, preferably 1.5 to 4.0 % by weight, particularly preferably 2.0 to 3.5 % by weight.
  • the adsorbed water content (% by weight) and the surface hydroxyl group content (% by weight) in the fine particle carrier are determined in the following manner.
  • the sample After a sample is dried at 200 °C under normal pressure in a stream of nitrogen for 4 hours, the sample is weighed, and a decrease in weight is obtained from the weights of the sample before and after dried. The obtained decrease in weight is expressed as a percentage to the weight of the sample before dried.
  • a carrier (sample) is dried at 200 °C under normal pressure in a stream of nitrogen for 4 hours, the carrier is weighed, and the obtained weight is taken as X (g). Further, after the carrier is calcined at 1,000 °C for 20 hours to remove the surface hydroxyl group, the carrier is weighed, and the obtained weight is taken as Y (g).
  • the transition metal compound of Group IVB metal of the periodic table containing a ligand having a cyclopentadienyl skeleton, which is used for forming the olefin polymerization catalyst of the invention is a transition metal compound represented by the following formula (Io). M1L x (Io)
  • M1 is a transition metal atom selected from Group VIB of the periodic table, for example, zirconium, titanium or hafnium, preferably zirconium.
  • x is a valence of the transition metal atom M1 and indicates the number of ligands L coordinated to the transition metal atom M1.
  • L is a ligand coordinated to the transition metal, and at least one of L is a ligand having a cyclopentadienyl skeleton.
  • L other than the ligand having a cyclopentadienyl skeleton is a hydrocarbon group of 1 to 12 carbon atoms, an alkoxy group, an aryloxy group, a trialkylsilyl group, SO3R1 group (wherein R1 is a hydrocarbon group of 1 to 8 carbon atoms which may have a substituent such as halogen), a halogen atom or hydrogen.
  • Examples of the ligands having a cyclopentadienyl skeleton include cyclopentadienyl group; alkyl-substituted cyclopentadienyl groups such as methylcyclopentadienyl, dimethylcyclopentadienyl, trimethylcyclopentadienyl, tetramethylcyclopentadienyl, pentamethylcyclopentadienyl, ethylcyclopentadienyl, methylethylcyclopentadienyl, propylcyclopentadienyl, methylpropylcyclopentadienyl, butylcyclopentadienyl, methylbutylcyclopentadienyl and hexylcyclopentadienyl; indenyl group; 4,5,6,7-tetrahydroindenyl group; and fluorenyl group. These groups may be substituted with halogen atoms
  • the ligands coordinated to the transition metal atom are preferably alkyl-substituted cyclopentadienyl groups.
  • the compound represented by the formula (Io) contains two or more groups having a cyclopentadienyl skeleton, two of them may be linked through an alkylene group, especially an alkylene group of 1 to 3 carbon atoms such as ethylene and propylene; a substituted alkylene group, especially a substituted alkylene group having a linkage moiety of 1 to 3 carbon atoms such as isopropylidene and diphenylmethylene; a silylene group; or a substituted silylene group such as dimethylsilylene, diphenylsilylene and methylsilylene.
  • linkage groups preferred are the alkylene groups and the substituted alkylene groups.
  • two or more ligands having cyclopentadienyl skeletons are preferably linked through the linkage group.
  • the ligands L other the ligand having a cyclopentadienyl skeleton are as follows.
  • hydrocarbon groups of 1 to 12 carbon atoms include an alkyl group, a cycloalkyl group, an aryl group and an aralkyl group.
  • alkyl groups such as methyl, ethyl, propyl, isopropyl and butyl
  • cycloalkyl groups such as cyclopentyl and cyclohexyl
  • aryl groups such as phenyl and tolyl
  • aralkyl groups such as benzyl and neophyl.
  • alkoxy groups examples include methoxy, ethoxy and butoxy.
  • aryloxy groups examples include phenoxy.
  • trialkylsilyl groups examples include trimethylsilyl.
  • Examples of the ligands represented by the SO3R1 group include p-toluenesulfonato, methanesulfonato, trifluoromethansulfonato.
  • halogen atoms examples include fluorine, chlorine, bromine and iodine.
  • the transition metal compound containing the ligand having a cyclopentadienyl skeleton is represented by the following formula (I'o): RR3R4R5M1 (I'o) wherein M1 is a transition metal atom selected from Group IVB of the periodic table similarly to the above, and is preferably zirconium, R is a group (ligand) having a cyclopentadienyl skeleton, R3, R4 and R5 are each a group (ligand) having a cyclopentadienyl skeleton, an alkyl group, a cycloalkyl group, an aryl group, an aralkyl group, an alkoxy group, an aryloxy group, a trialkylsilyl group, SO3R1 group, a halogen atom or hydrogen.
  • M1 is a transition metal atom selected from Group IVB of the periodic table similarly to the above, and is preferably zirconium
  • R is a group (ligand
  • transition metal compounds represented by the formula (I'o) preferably used in the invention are those in which at least one of R3, R4 and R5 is a group (ligand) having a cyclopentadienyl skeleton, for example, those in which R and R3 are each a group (ligand) having a cyclopentadienyl skeleton.
  • R3, R4 and R5 is a group (ligand) having a cyclopentadienyl skeleton
  • R and R3 are each a group (ligand) having a cyclopentadienyl skeleton.
  • the compound represented by the above formula (I'o) contains two or more groups (ligands) having a cyclopentadienyl group, two of them may be linked through the same (substituted) alkylene group or (substituted) silylene group as described above.
  • R and R3 are each a group (ligand) having a cyclopentadienyl skeleton
  • R4 and R5 are each a group (ligand) having a cyclopentadienyl skeleton, an alkyl group, a cycloalkyl group, an aryl group, an aralkyl group, an alkoxy group, an aryloxy group, a trialkylsilyl group, SO3R1 group, a halogen atom or hydrogen.
  • transition metal compounds represented by the formula (Io) and containing zirconium as M1 are examples of the transition metal compounds represented by the formula (Io) and containing zirconium as M1.
  • the di-substituents of the cyclopentadienyl ring include 1,2- and 1,3-substituents, and the tri-substituents thereof include 1,2,3- and 1,2,4-substituents.
  • the alkyl groups such as propyl and butyl include isomers such as n-, i-, sec- and tert-alkyl groups.
  • organoaluminum oxy-compound (B) for forming the olefin polymerization catalyst of the invention is described.
  • the organoaluminum oxy-compound (B) may be either aluminoxane conventionally known or such a benzeneinsoluble organoaluminum oxy-compound as exemplified in Japanese Patent Laid-Open Publication No. 78687/1990.
  • a preferred embodiment of the organoaluminum oxy-compound (B) used in the invention is an organoaluminum oxy-compound having a molar ratio of alkyl group to aluminum atom contained therein (R/Al ratio) of not less than 1.3 and less than 1.7, preferably not less than 1.4 and less than 1.7.
  • the organoaluminum oxy-compound presumably contains an alkylaluminum oxy-compound represented by the following formula (i) or (ii) as its major component and contains a small amount of an organoaluminum compound such as trialkylaluminum.
  • the alkyl group in the organoaluminum oxy-compound means the total of the alkyl group (R') in the alkylaluminum oxy-compound and the alkyl group (R") in the organoaluminum compound
  • the aluminum atom in the organoaluminum oxy-compound means the total of the aluminum atom (Al') in the alkylaluminum oxy-compound and the aluminum atom (Al'') in the organoaluminum compound. That is, the R/Al ratio in this specification means a ratio of the alkyl group (R'+R'') to the aluminum atom (Al'+Al'')
  • the amount of the aluminum atom in the organoaluminum oxy-compound is measured in the following manner in accordance with plasma emission spectral analysis (ICP).
  • the olefin polymerization catalyst containing the organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 By the use of the olefin polymerization catalyst containing the organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7, a polymer having a particle diameter of not more than 100 ⁇ m (fine-powdery polymer) is hardly produced in the polymerization procedure, and a polymer of excellent particle properties can be obtained. Moreover, when the olefin polymerization catalyst containing the organoaluminum oxy-compound is prepolymerized, a polymerized catalyst having excellent particle-forming properties can be prepared.
  • the organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 a commercially available aluminoxane having the above-defined R/Al ratio is employable, or the organoaluminum oxy-compound can be prepared by a process similar to that for preparing the later-described organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1. That is, the organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 can be prepared by the following processes:
  • organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 is prepared by the above processes, the same conditions as those for preparing the later-described organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1 can be adopted.
  • organoaluminum oxy-compound (B) used in the invention is an organoaluminum oxy-compound having a molar ratio of alkyl group to aluminum atom contained therein (R/Al ratio) of 1.7 to 2.1, preferably 1.8 to 2.1, more preferably 1.9 to 2.1
  • the olefin polymerization catalyst containing the organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1 By the use of the olefin polymerization catalyst containing the organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1, a polymer having a particle diameter of not more than 100 ⁇ m (fine-powdery polymer) is hardly produced in the polymerization procedure, and a polymer of excellent particle properties can be obtained. Moreover, when the olefin polymerization catalyst containing the organoaluminum oxy-compound is prepolymerized, a prepolymerized catalyst having excellent particle properties can be prepared.
  • the organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1 can be prepared by, for example, the following processes:
  • the aluminoxane is on the market generally in the form of a solution, and in this case the solution can be used as it is.
  • the solution of aluminoxane may further contain other ingredients, with the proviso that no adverse effect is given to the reaction.
  • the organoaluminum oxy-compound before adjusted in the R/Al ratio is sometimes referred to as "starting organoaluminum oxy-compound" hereinafter.
  • a starting organoaluminum oxy-compound is brought into contact with water, whereby an organoaluminum compound in the starting organoaluminum oxy-compound reacts with water thereby to adjust the R/Al ratio.
  • a starting organoaluminum oxy-compound having an R/Al ratio of more than 2.1 can be brought into contact with water to prepare a starting organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1, or a (starting) organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 can be brought into contact with water to adjust the R/Al ratio to a specific value within the range of 1.7 to 2.1.
  • the water to be brought into contact with the starting organoaluminum oxy-compound may be in the form of either liquid, gas or solid.
  • adsorbed water adsorbed on inorganic compounds such as silica, alumina and aluminum hydroxide or polymer
  • inorganic compounds such as silica, alumina and aluminum hydroxide or polymer
  • hydrocarbon solvents such as benzene, toluene and hexane
  • ether solvents such as tetrahydrofuran
  • amine solvents such as triethylamine
  • water of crystallization of salts such as magnesium chloride, magnesium sulfate, aluminum sulfate, copper sulfate, nickel sulfate, ferrous sulfate and cerous chloride.
  • the adsorbed water adsorbed on the inorganic compounds is preferably employed.
  • the adsorbed water on the aforementioned fine particle carrier can be also used as the water to be brought into contact with the starting organoaluminum oxy-compound.
  • the contact is carried out generally in an organic medium.
  • organic media used herein examples include: hydrocarbon solvents, such as aromatic hydrocarbons (e.g., benzene, toluene, xylene, cumene and cymene), aliphatic hydrocarbons (e.g., pentane, hexane, heptane, octane, decane, dodecane, hexadecane and octadecane), alicyclic hydrocarbons (e.g., cyclopentane, cyclohexane, cyclooctane and methylcyclohexane), and petroleum fractions (e.g., gasoline, kerosine and petroleum fraction); halogenated hydrocarbons, such as halides of the above-mentioned aromatic hydrocarbons, aliphatic hydrocarbons and alicyclic hydrocarbons, particularly chlorides and bromides; and ethers, such as ethyl ether and tetrahydrofuran
  • aromatic hydrocarbons are particularly preferred.
  • the water to be brought into contact with the starting organoaluminum oxy-compound is used in an amount of 0.01 to 0.3 mol, preferably 0.02 to 0.2 mol, more preferably 0.03 to 0.15 mol, based on 1 mol of the aluminum atom in the starting organoaluminum oxy-compound.
  • the concentration of the starting organoaluminum oxy-compound in the reaction system is in the range of usually 1 ⁇ 10 ⁇ 3 to 5 g ⁇ atom/liter-solvent, preferably 1 ⁇ 10 ⁇ to 3 g ⁇ atom/liter-solvent, in terms of the aluminum atom in the starting organoaluminum oxy-compound; and the concentration of water in the reaction system is in the range of usually 0.01 to 1 mol/liter-solvent, preferably 0.02 to 0.5 mol/liter-solvent.
  • the contact of the starting organoaluminum oxy-compound with water is carried out at a temperature of usually -50 to 150 °C, preferably 0 to 120 °C, more preferably 20 to 100 °C.
  • the contact time is in the range of usually 0.5 to 300 hours, preferably 1 to 150 hours, though it greatly varies according to the contact temperature.
  • the contact of the starting organoaluminum oxy-compound with water is carried out in the following manner.
  • a starting organoaluminum oxy-compound having an R/Al ratio of less than 1.7 or more than 2.1 is brought into contact with an inorganic compound substantially not containing water thereby to prepare an organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1.
  • the expression "substantially not containing water” means that the adsorbed water content in the inorganic compound is not more than 0.1 % by weight.
  • the specific component in the starting organoaluminum oxy-compound e.g., an alkylaluminum oxy-compound having a specific R/Al ratio
  • the inorganic compound used herein is an inorganic compound substantially not containing water.
  • a compound having a surface hydroxyl group can vary the R/Al ratio by the function of the hydroxyl group.
  • Examples of the inorganic compounds to be brought into contact with the starting organoaluminum oxy-compound include silica, alumina and aluminum hydroxide.
  • the inorganic compound desirably has a surface hydroxyl group content of not less than 1.0 % by weight, preferably 1.5 to 4.0 % by weight, particularly preferably 2.0 to 3.5 % by weight, and has an adsorbed water content of not more than 0.1 % by weight, preferably not more than 0.01 % by weight.
  • the inorganic compound has a particle diameter of 10 to 300 ⁇ m, preferably 20 to 200 ⁇ m, and a specific surface area of 50 to 1,000 m/g, preferably 100 to 700 m/g.
  • the adsorbed water content (% by weight) and the surface hydroxyl group content (% by weight) can be determined in the same manner as described for the fine particle carrier.
  • the contact of the starting organoaluminum oxy-compound with the inorganic compound substantially not containing water is carried out generally in an organic medium.
  • organic media used herein include the aforesaid hydrocarbons, halogenated hydrocarbons and ethers. Of the organic media, aromatic hydrocarbons are particularly preferred.
  • the inorganic compound substantially not containing water, which is to be brought into contact with the starting organoaluminum oxy-compound is used in an amount of 1 to 50 % by mol, preferably 5 to 45 % by mol, more preferably 10 to 40 % by mol, based on the amount of the aluminum atom in the starting organoaluminum oxy-compound. It is desired that the concentration of the starting organoaluminum oxy-compound in the reaction system is in the range of usually 1 ⁇ 10 ⁇ 3 to 5 g ⁇ atom/liter-solvent, preferably 1 ⁇ 10 ⁇ to 3 g ⁇ atom/liter-solvent, in terms of the aluminum atom in the starting organoaluminum oxy-compound.
  • the contact of the starting organoaluminum oxy-compound with the inorganic compound substantially not containing water is carried out at a temperature of usually -50 to 150 °C, preferably 0 to 120 °C, more preferably 20 to 100 °C.
  • the contact time is in the range of usually 0.5 to 300 hours, preferably 1 to 150 hours, though it greatly varies according to the contact temperature.
  • a solvent is temporarily evaporated from a solution of the starting organoaluminum oxy-compound having an R/Al ratio of more than 2.1 to dry the organoaluminum oxy-compound, and the dried organoaluminum oxy-compound is redissolved in a solvent to prepare an organoaluminum oxy-compound having an R/Al ratio of 1.3 to 1.7.
  • the temperature for evaporating the solvent is in the range of 10 to 100 °C, preferably 20 to 50 °C, and the pressure therefor is in the range of 2 to 100 mmHg, preferably 5 to 40 mmHg.
  • the solvents for dissolving the dried organoaluminum oxy-compound include the aforesaid organic media used in the process (a). Of the organic media, aromatic hydrocarbons are preferred.
  • the processes (a), (b) and (c) may be used in combination.
  • the R/Al ratio of the (starting) organoaluminum oxy-compound is adjusted to 1.7 to 2.1 by the process (a) and then the R/Al ratio is adjusted to a specific value within the range of 1.7 to 2.1 by the process (b). Also possible is that the R/Al ratio of the (starting) organoaluminum oxy-compound is adjusted to 1.7 to 2.1 by the process (b) and then the R/Al ratio is adjusted to a specific value within the range of 1.7 to 2.1 by the process (a).
  • a proportion of the organoaluminum compound contained therein is preferably in the specific range.
  • the organoaluminum oxy-compound is methylaluminoxane containing trimethylaluminum
  • each of said peak areas being measured from 1H-NMR is in the range of 0.25 to 0.40, preferably 0.27 to 0.40, more preferably 0.30 to 0.40.
  • the peak area derived from proton in the methylaluminoxane and the peak area derived from proton in the trimethylaluminum (TMA) can be determined in the following manner.
  • a sample tube having an inner diameter of 5 mm 0.5 ml of a toluene solution of an organoaluminum oxy-compound (0.5 - 1.5 mol/liter) is mixed with 0.1 ml of deuterated benzene to conduct sample adjustment, and the 1H-NMR of the sample is measured under the conditions of ordinary temperature, a measuring frequency of 500 MHz, a spectral width of 7507.5 Hz, a pulse repetition time of 6.2 seconds, a pulse width of 45°.
  • a broad peak seen at about -0.6 ppm to 0.3 ppm is assigned to a peak derived from proton in the methylaluminoxane and a sharp peak seen at about -0.28 ppm is assigned to a peak derived from proton in the trimethylaluminum (TMA) (see: Fig. 1).
  • TMA trimethylaluminum
  • the peak area is determined by curve fitting using Lorentz's function (see: Fig. 2).
  • the olefin polymerization catalyst of the invention contains the fine particle carrier, the transition metal compound (A) and the organoaluminum oxy-compound (B) as its essential components, but it may further contain an organoaluminum compound (C) described below, if necessary.
  • the organoaluminum compound (C) which may be used if necessary is, for example, an organoaluminum compound represented by the following formula (II): R a n AlX 3-n (II) wherein R a is a hydrocarbon group of 1 to 12 carbon atoms, X is a halogen atom or hydrogen, and n is 1 to 3.
  • R a is a hydrocarbon group of 1 to 12 carbon atoms, for example, an alkyl group, a cycloalkyl group or an aryl group. Particular examples thereof include alkyl groups, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, pentyl, hexyl, isohexyl, heptyl, nonyl and octyl; cycloalkyl groups such as cyclopentyl and cyclohexyl; and aryl groups such as phenyl and tolyl.
  • alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, pentyl, hexyl, isohexyl, heptyl, nonyl and octyl
  • cycloalkyl groups such as cycl
  • organoaluminum compounds (C) include: trialkylaluminums, such as trimethylaluminum, triethylaluminum, triisopropylaluminum, triisobutylaluminum, trioctylaluminum and tri-2-ethylhexylaluminum; alkenylaluminums, such as isoprenylaluminum; dialkylaluminum halides, such as dimethylaluminum chloride, diethylaluminum chloride, diisopropylaluminum chloride, diisobutylaluminum chloride and dimethylaluminum bromide; alkylaluminum sesquihalides, such as methylaluminum sesquichoride, ethylaluminum sesquichloride, isopropylaluminum sesquichloride, butylaluminum sesquichloride and ethylaluminum sesquibromide; alkylaluminums,
  • organoaluminum compound (C) is a compound represented by the following formula (III): R a n AlY 3-n (III) wherein R a is the same as above; Y is -OR b group, -OSiR c 3 group, OAlR d 2 group, -NR e 2 group, -SiR f 3 group or -N(R g )AlR h 2 group; n is 1 to 2; R b , R c , R d and R h are each methyl, ethyl, isopropyl, isobutyl, cyclohexyl, phenyl or the like, R e is hydrogen, methyl, ethyl, isopropyl, phenyl, trimethylsilyl or the like; and R f and R g are each methyl, ethyl or the like.
  • organoaluminum compounds examples include:
  • organoaluminum compounds represented by the formulas (II) and (III) preferred are compounds of the formulas R a 3Al, R a n Al(OR b ) 3-n and R a n Al(OAlR d 2) 3-n , and particularly preferred are compounds of said formulas in which R a is an isoalkyl group and n is 2.
  • the olefin polymerization catalyst of the invention may further contain other components useful for olefin polymerization in addition to the above-described components.
  • One preferred embodiment of the olefin polymerization catalyst of the invention is a solid catalyst (component) comprising the fine particle carrier, the transition metal compound (A) and the organoaluminum oxy-compound (B), and if necessary, the organoaluminum compound (C), said components (A), (B) and (C) being supported on the fine particle carrier.
  • Such olefin polymerization catalyst can be prepared by mixing and contacting the fine particle carrier, the transition metal compound (A) and the organoaluminum oxy-compound (B), and if necessary, the organoaluminum compound (C), with each other in an inert hydrocarbon solvent.
  • Fig. 3 shows steps of a process for preparing the olefin polymerization catalyst of the invention.
  • the sequence of the mixing operations is arbitrarily determined. For example, it is possible that the fine particle carrier is contacted with the organoaluminum oxy-compound (B) and then the resultant product is contacted with the transition metal compound (A), but it is desired that a mixture of the organoaluminum oxy-compound (B) and the transition metal compound (A) is contacted with the fine particle carrier.
  • Examples of the inert hydrocarbon solvents used for preparing the olefin polymerization catalyst include: aliphatic hydrocarbons, such as propane, butane, pentane, hexane, heptane, octane, decane, dodecane and kerosine; alicyclic hydrocarbons, such as cyclopentane, cyclohexane and methylcyclopentane; aromatic hydrocarbons, such as benzene, toluene and xylene; halogenated hydrocarbons, such as ethylene chloride, chlorobenzene and dichloromethane; and mixtures of these hydrocarbons.
  • aliphatic hydrocarbons such as propane, butane, pentane, hexane, heptane, octane, decane, dodecane and kerosine
  • alicyclic hydrocarbons such as cyclopentane, cyclohexane and methyl
  • the transition metal compound (A) is used in an amount of usually 5 ⁇ 10 ⁇ 6 to 5 ⁇ 10 ⁇ 4 mol, preferably 10 ⁇ 5 to 2 ⁇ 10 ⁇ 4 mol, per 1 g of the fine particle carrier, and the concentration of the transition metal compound (A) is in the range of about 10 ⁇ 4 to 2 ⁇ 10 ⁇ mol/liter-solvent, preferably 2 ⁇ 10 ⁇ 4 to 10 ⁇ mol/liter-solvent.
  • An atomic ratio of the aluminum atom (Al) in the organoaluminum oxy-compound (B) to the transition metal (M) in the transition metal compound (A), Al/M is in the range of usually 10 to 500, preferably 20 to 200.
  • the organoaluminum compound (C), which may be added if necessary, is desirably used in an amount of not more than 500 mol, preferably 5 to 200 mol, per 1 g ⁇ atom of the transition metal atom in the transition metal compound (A).
  • the temperature for mixing the components is in the range of usually -50 to 150 °C, preferably -20 to 120 °C, and the contact time is in the range of 1 to 1,000 minutes, preferably 5 to 600 minutes.
  • the temperature may be varied in the mixing procedure.
  • the olefin polymerization catalyst (solid catalyst) of the invention has a bulk density of which lower limit is not less than 0.3 g/cm3, preferably not less than 0.4 g/cm3, and upper limit may be not more than 0.5 g/cm3, preferably not more than 0.45 g/cm3, and has a fluidity index of not less than 45, preferably 50 to 70.
  • the fluidity index is obtained by using the solid catalyst which is prepared by removing a supernatant liquid from the resulting mixture of the contact in an inert medium of the components (A) and (B), and the optional component (C) to separate a catalyst, washing the separated catalyst with hexane two times, separating the slid by a glass filter (G3) and drying the separated solid under reduced pressure at an ordinary temperature for two hours.
  • the fluidity index is calculated by adding indices of a degree of compaction, an angle of repose and an angle of spatula.
  • the three properties are selected from the degree of compaction, the angle of repose, the angle of spatula and the degree of cohesion which are made indices in order to calculate the fluidity index in the fluidity evaluation method of Carr, R.L. et al. (Chem. Eng., 72, (2) 163, (3) 69, 1965).
  • the description of "Practical method for measuring dynamical and mechanical properties of powders" in Chemical Engineering Handbook pp. 253 - 255, Chemical Engineering Association, 5th Edition, Maruzen K.K. in Japan (1988) can be also referred.
  • Multi-Tester MT-1000 multi-performance type instrument for physical properties: manufactured by Kabushiki Kaisha Senshinkigyo) under nitrogen atmosphere.
  • the degree of compaction is calculated from a loose density ( ⁇ p ) and a compacted density ( ⁇ a ) by the following formula.
  • Cp 100 x ( ⁇ p - ⁇ a)/ ⁇ p
  • the loose density ( ⁇ a ) is a ratio of the weight (W1) to the volume (V) of a powder in a vessel into which the powder is gently introduced followed by removing the heaping portions from the top of the vessel.
  • ⁇ a W1/V
  • ⁇ p W2/V.
  • the angle of Repose ( ⁇ r) is measured by the Multi-Tester in accordance with the changing angle method.
  • the powder is dropped from an upper funnel on a table for measuring the angle of repose to heap up the powder thereon and the angle of the heaped-up powder on the table is measured as the angle of repose ( ⁇ r).
  • a spatula (plate) is embedded in a powder followed by rising the spatula upward and the angle of the heaped-up powder on the spatula is measured as the angle of spatula ( ⁇ s).
  • the angle of spatula is an average of an angle ( ⁇ s1 ) when the spatula is gently risen and an angle ( ⁇ s2 ) when the spatula is risen followed by giving a shock to remove a loose portion of the heaped-up powder.
  • ⁇ s ( ⁇ s1 + ⁇ s2 ) / 2
  • the fluidity index in the present specification is 75 at most.
  • the olefin polymerization catalyst (solid catalyst) of the invention hardly produces a fine-powdery polymer having a particle diameter of not more than 100 ⁇ m and can prepare an olefin polymer of excellent particle properties. Further, the olefin polymerization catalyst (solid catalyst), which contains an organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 or an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 and which has the above-defined bulk density and fluidity index, hardly produces a fine-powdery polymer and can prepare a polymer of excellent particle properties.
  • olefin polymerization catalyst of the invention is a prepolymerized catalyst formed from the fine particle carrier, the transition metal compound (A), the organoaluminum oxy-compound (B), the organoaluminum compound (C) used optionally and an olefin polymer produced by prepolymerization.
  • Such olefin polymerization catalyst can be prepared by introducing an olefin into an inert hydrocarbon solvent in the presence of the fine particle carrier, the transition metal compound (A) and the organoaluminum oxy-compound (B), and if necessary, the organoaluminum compound (C). It is preferred that the fine particle carrier, the transition metal compound (A) and the organoaluminum oxy-compound (B) together form a solid catalyst (component). In this case, the organoaluminum oxy-compound (B) may be further added in addition to the solid catalyst (component).
  • olefins used for the prepolymerization examples include ⁇ -olefins of 2 to 20 carbon atoms, such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene and 1-tetradecene. Of these, preferred is ethylene or a combination of ethylene and the same ⁇ -olefin as used in the polymerization.
  • Examples of the inert hydrocarbon solvents used for the prepolymerization are identical with those used for preparing the aforesaid solid catalyst.
  • the transition metal compound (A) is used in an amount of usually 10 ⁇ 6 to 2 ⁇ 10 ⁇ mol/liter-solvent, preferably 5 ⁇ 10 ⁇ 5 to 10 ⁇ mol/liter, in terms of the transition metal atom in the transition metal compound (A), and this compound (A) is used in an amount of usually 5 ⁇ 10 ⁇ 6 to 5 ⁇ 10 ⁇ 4 mol, preferably 10 ⁇ 5 to 2 ⁇ 10 ⁇ 4 mol, per 1 g of the fine particle carrier.
  • An atomic ratio of the aluminum atom (Al) in the organoaluminum oxy-compound (B) to the transition metal (M) in the transition metal compound (A), Al/M, is in the range of usually 10 to 500, preferably 20 to 200.
  • a ratio of the aluminum atom (Al-C) in the organoaluminum compound (C) to the aluminum atom (Al-B) in the organoaluminum oxy-compound (B), Al-C/Al-B, is in the range of usually 0.02 to 3, preferably 0.05 to 1.5.
  • the prepolymerization temperature is in the range of -20 to 80 °C, preferably 0 to 50 °C, and the prepolymerization time is in the range of 0.5 to 100 hours, preferably 1 to 50 hours.
  • the amount of the polymer produced in the prepolymerization is desirably in the range of about 0.1 to 500 g, preferably 0.3 to 300 g, particularly preferably 1 to 100 g, per 1 g of the fine particle carrier.
  • the transition metal atom is supported in an amount of about 5 ⁇ 10 ⁇ 6 to 5 ⁇ 10 ⁇ 4 g ⁇ atom, preferably 10 ⁇ 5 to 2 ⁇ 10 ⁇ 4 g ⁇ atom, per 1 g of the fine particle carrier, and the aluminum atom derived from both the organoaluminum oxy-compound (B) and the organoaluminum compound (C) is supported in an amount of about 10 ⁇ 3 to 5 ⁇ 10 ⁇ g ⁇ atom, preferably 2 ⁇ 10 ⁇ 3 to 2 ⁇ 10 ⁇ g ⁇ atom, per 1 g of the fine particle carrier.
  • the olefin polymerization catalyst (prepolymerized catalyst) of the invention has a bulk density of which lower limit is not less than 0.3 g/cm3, preferably not less than 0.4 g/cm3, and upper limit may be not more than 0.5 g/cm3, preferably not more than 0.45 g/cm3, and has a fluidity index of not less than 45, preferably 50 to 70.
  • the fluidity index of the prepolymerized catalyst is measured in the same manner as in the case of the fluidity index of the solid catalyst.
  • the olefin polymerization catalyst (prepolymerized catalyst) of the invention is excellent in particle-forming properties. If an olefin is polymerized using such catalyst, a fine-powdery polymer having a particle diameter of not more than 100 ⁇ m is hardly produced, and an olefin polymer of excellent particle properties can be prepared.
  • the olefin polymerization catalyst which contains an organoaluminum oxy-compound having an R/Al ratio of not less than 1.3 and less than 1.7 or an organoaluminum oxy-compound having been adjusted to have an R/Al ratio of 1.7 to 2.1 and which has the above-defined bulk density and fluidity index, hardly produces a fine-powdery polymer and can prepare a polymer of excellent particle properties.
  • the olefin polymerization catalyst of the invention may further contain other components useful for olefin pqlymerization in addition to the above-described components.
  • polymerization of an olefin or copolymerization of two or more olefins is carried out in the presence of the above-described olefin polymerization catalyst.
  • the polymerization can be conducted by any of a liquid phase polymerization process such as a suspension polymerization process and a gas phase polymerization process.
  • the same inert hydrocarbon solvent as used for preparing the catalyst is employable, or the olefin itself is also employable as the solvent.
  • the catalyst is desirably used in such an amount that the concentration of the transition metal atom of the transition metal compound (A) in the polymerization system is in the range of usually 10 ⁇ 8 to 10 ⁇ 3 g ⁇ atom/liter, preferably 10 ⁇ 7 to 10 ⁇ 4 g ⁇ atom/liter.
  • an organoaluminum oxy-compound and/or an organoaluminum compound which is not supported may be further added.
  • the temperature for olefin polymerization is in the range of usually -50 to 100 °C, preferably 0 to 90 °C; in the liquid phase polymerization process, it is in the range of usually 0 to 250 °C, preferably 20 to 200 °C; and in the gas phase polymerization process, it is in the range of usually 0 to 120 °C, preferably 20 to 100 °C.
  • the polymerization pressure is in the range of usually atmospheric pressure to 100 kg/cm, preferably atmospheric pressure to 50 kg/cm.
  • the polymerization reaction can be carried out either batchwise, semi-continuously or continuously. Further, the polymerization may be carried out in two or more stages different in the reaction conditions.
  • the molecular weight of the resulting olefin polymer can be regulated by allowing hydrogen to exist in the polymerization system or varying the polymerization temperature.
  • the transition metal compound (A) is specifically the below-described transition metal compound
  • the organoaluminum oxy-compound (B) is an organoaluminum oxy-compound having a molar ratio of alkyl group to aluminum atom (alkyl group/aluminum atom) of not more than 1.8.
  • the propylene polymerization catalyst is a solid catalyst comprising: a fine particle carrier,
  • M1 is a transition metal atom of Groups IV - VIB of the periodic table, and includes zirconium, titanium, hafnium, vandium, niobium, tantalum, chromium, molbdenum and tungsten. M1 is preferably zirconium, titanium or hafnium.
  • R1, R, R3 and R4 may be the same as or different from each other, and are each a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, a silicon-containing group, a oxygen-containing group, a sulfur-containing group, a nitrogen-containing group, a phosphorus-containing compound, a hydrogen atom or a halogen atom.
  • a part of adjacent groups may be bonded with each other to form a ring together with carbon atoms to which the bonded groups are attached.
  • R1, R, R3 and R4 are each presents two times and the two groups, for example R1 and R1 are the same as or different from each other. Moreover, groups represented by R having the same suffix are those which makes a preferable combination for being bonded with each other to form the ring.
  • the hydrocarbon group of 1 to 20 carbon atoms includes, alkyl groups such as methyl, ethyl, propyl, butyl, hexyl, octyl, nonyl, dodecyl and icosyl; cycloalkyl groups such as cyclopentyl, cyclohexyl, norbornyl and adamantyl; alkyl groups such as vinyl, propenyl and cyclohexenyl; arylalkyl groups such as benzyl, phenylethyl and phenylpropyl and aryl groups such as phenyl, tolyl, dimethylphenyl, trimethylphenyl, ethylphenyl, propylphenyl, biphenyl, naphtyl, methylnaphthyl, anthracenyl and phenanthryl.
  • alkyl groups such as methyl, ethyl, propyl, butyl
  • the ring formed by bonding the hydrocarbon groups with each other includes condensed rings such as benzene ring, naphthalene ring, acenaphthene ring and indene ring; and groups in which hydrogen of the condensed rings (e.g. benzene ring, naphthalene ring, acenaphthene ring and indene ring) is replaced with an alkyl group such as methyl, ethyl, propyl and butyl.
  • condensed rings such as benzene ring, naphthalene ring, acenaphthene ring and indene ring
  • groups in which hydrogen of the condensed rings e.g. benzene ring, naphthalene ring, acenaphthene ring and indene ring
  • an alkyl group such as methyl, ethyl, propyl and butyl.
  • halogenated hydrocarbon group examples include halogenated hydrocarbon groups in which a hydrogen of the above-mentioned hydrocarbon is substituted with a halogen.
  • silicon-containing group examples include such as monohydrocarbon-substituted silyl (e.g. methylsilyl and phenylsilyl); dihydrocarbon-substituted silyl (e.g. dimethylsilyl and diphenylsilyl); trihydrocarbon-substituted silyl (e.g.
  • silyl ether of hydrocarbon-substituted silyl e.g. trimethyl silyl ether
  • silicon-substituted alkyl e.g. trimethylsilylmethyl
  • silicon-substituted aryl e.g. trimethylsilylphenyl
  • the silicon-containing group includes -SiR3 (wherein R is halogen atom, alkyl of 1 to 10 carbon atoms or aryl of 6 to 10 carbon atoms) other than those described above.
  • oxygen-containing group examples include hydroxyl group; alkoxy groups, such as methoxy, ethoxy, propoxy and butoxy; aryloxy groups, such as phenoxy, methylphenoxy, dimethylphenoxy and naphthoxy; and arylalkoxy groups, such as phenylmethoxy and phenylethoxy.
  • the oxygen-containing group includes -OR (wherein R is halogen atom, alkyl of 1 to 10 carbon atoms or aryl of 6 to 10 carbon atoms) other than those described above.
  • sulfur-containing groups include substituents obtained by replacing oxygen with sulfur in the above-mentioned oxygen-containing groups.
  • the sulfur-containing groups includes -SR (wherein R is halogen atom, alkyl of 1 to 10 carbon atoms or aryl of 6 to 10 carbon atoms) other than those described above.
  • nitrogen-containing groups examples include amino groups; alkylamino groups such as methylamino, dimetylamino, diethylamino, dipropylamino, dibutylamino and dicyclohexylamino; and arylamino groups or alkylaryl groups such as phenylamino, diphenylamino, ditolylamino, dinaphthylamino and methylphenylamino.
  • the nitrogen-containing group includes -NR2 (wherein R is halogene atom, alkyl of 1 to 10 carbon atoms or aryl of 6 to 10 carbon atoms) other than those described above.
  • Examples of the phosphorus-containing groups include phosphino groups such as dimethylphosphino and diphenylphosphino.
  • the phosphorus-containing group includes -PR2 (wherein R is halogene atom, alkyl of 1 to 10 carbon atoms or aryl of 6 to 10 carbon atoms) other than those described above.
  • halogen examples include fluorine, chlorine, bromine and iodine.
  • hydrocarbon groups especially hydrocarbon groups of 1 to 4 carbon atoms such as methyl, ethyl, propyl and butyl; benzene ring formed by bonding hydrocarbon groups; and groups in which hydrogen of benzene ring formed by bonding hydrocarbon groups is substituted with a alkyl group such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl and tert-butyl.
  • X1 and X are the same as or different from each other, and are each hydrocarbon group, a halogenated hydrocarbon group, an oxygen-containing group, a sulfur-containing group , a silicone-containing compound, hydrogen and halogen atom.
  • the hydrocarbon groups are preferably hydrocarbon groups of 1 to 20 carbon atoms and are identical with those described above for R1, R, R3 and R4.
  • the halogenated hydrocarbon groups are preferably hydrocarbon groups of 1 to 20 carbon atoms and are identical with those described for R1, R, R3 and R4.
  • oxygen-containing groups and the halogen atoms are identical with those described for R1, R, R3 and R4.
  • sulfur-containing groups include those identical with R1, R, R3 and R4; sulfonato groups such as methylsulfonato, trifluoromethanesulfonato, phenylsulfonato, benzylsulfonato, p-toluenesulfonato, trimethylbenzenesulfonato, triisobutylbenzenesulfonato, p-chlorobenzenesulfonato and pentafluorobenzenesulfonato; and sulfinato groups such as methylsulfinato, phenylsulfinato, benzenesulfinato, p-toluenesulfinato, trimethylbenzenesulfinato and pentafluorobenzenesulfinato.
  • sulfonato groups such as methylsulfonato,
  • the silicon-containing group includes those identical with the aforementioned silicone-substituted alkyl groups and silicon-substituted aryl groups.
  • halogen atoms hydrocarbon groups of 1 to 20 carbon atoms.
  • Y is a divalent hydrocarbon group, a divalent halogenated hydrocarbon, a divalent silicon-containing group, a divalent germanium-containing group, a divalent tin-containing group -O-, -CO-, -S-, -SO-, -SO2-, -Ge-, -Sn-, -NR5-, -P(R5)-, -P(O) (R5)-, -BR5- or -AlR5- (wherein R5 is hydrogen, a halogen atom, a hydrocarbon group, a halogenated hydrocarbon group or an alkoxy group).
  • the divalent hydrocarbon group is preferably divalent hydrocarbon groups of 1 to 20 carbon atoms which include alkylene groups, such as methylene, dimethylmethylene, 1,2-ethylene, dimethyl-1,2-ethylene, 1,3-trimethylene, 1,4-tetramethylene, 1,2-cyclohexylene and 1,4-cyclohexylene; and arylalkylene groups, such as diphenylmethylene and diphenyl-1,2-ethylene.
  • alkylene groups such as methylene, dimethylmethylene, 1,2-ethylene, dimethyl-1,2-ethylene, 1,3-trimethylene, 1,4-tetramethylene, 1,2-cyclohexylene and 1,4-cyclohexylene
  • arylalkylene groups such as diphenylmethylene and diphenyl-1,2-ethylene.
  • the divalent halogenated hydrocarbon groups is preferably divalent halogenated hydrocarbon groups of 1 to 20 carbon atoms which include those obtained by halogenating the above-mentioned divalent hydrocarbon groups of 1 to 20 carbon atoms, such as chloromethylene.
  • divalent silicon-containing groups examples include alkylsilylene groups such as methylsilylene, dimethylsilylene, diethylsilylene, di(n-propyl)silylene, di(i-propyl)silylene, di(cyclohexyl)silylene, methylphenylsilylene, diphenylsilylene, di(p-tolyl)silylene and di(p-chlorophenyl)silylene; alkyldisilyl groups such as alkylarylsilylene group; arylsilylene groups, tetramethyl-1,2-disilyl and tetraphenyl-1,2-disilyl groups; and alkylaryldisilyl aryldisilyl groups.
  • alkylsilylene groups such as methylsilylene, dimethylsilylene, diethylsilylene, di(n-propyl)silylene, di(i-propyl)silylene, di(cyclohexy
  • divalent germanium-containing groups examples include those obtained by replacing silicon with germanium in the above-mentioned divalent silicon-containing groups.
  • substituted sylylene groups such as dimethylsilylene, diphenylsilylene and methylphenylsilylene.
  • transition metal compounds represented by the formula (Ia) rac-Dimethylsilylene-bis(2,3,5-trimethylcyclopentadienyl)zirconium dichloride, rac-Dimethylsilylene-bis(2,4-dimethylcyclopentadienyl)zirconium dichloride, rac-Dimethylsilylene-bis(2-methyl-4-tert-butylcyclopentadienyl)zirconium dichloride, Isopropylidene-(4-methylcyclopentadienyl) (3- methylindenyl)zirconium dichloride, rac-Dimethylsilylene-bis(isopropylidene-(4-tert-butylcyclopentadienyl) (3-tert-butylindenyl)zirconium dichloride, Isopropylidene-(4-tert-butylcyclopentadienyl) (3-tert-butylindeny
  • Example of the transition compounds represented by the formula (I) is at least one of the transition compounds represented by the formulae (Ia), (Ib) and (Ic).
  • M1 is a transition metal atom of Group IVB of the periodic table, for example, titanium, zirconium or hafnium, preferably zirconium.
  • R11 is a hydrocarbon group of 1 to 6 carbon atoms, and examples thereof include alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, neopentyl, n-hexyl and cyclohexyl, and alkenyl groups such as vinyl and propenyl.
  • alkyl groups whose carbon atoms bonded to the indenyl group are primary carbon atoms, more preferred are alkyl groups of 1 to 4 carbon atoms, and particularly preferred are methyl and ethyl.
  • R1, R14, R15 and R16 may be the same as or different from each other, and are each hydrogen, a halogen atom or a hydrocarbon group of 1 to 6 carbon atoms.
  • R13 is hydrogen or an aryl group of 6 to 16 carbon atoms.
  • the aryl groups of 6 to 16 carbon atoms include phenyl, ⁇ -naphthyl, ⁇ -naphthyl, anthracenyl, phenanthryl, pyrenyl, acenaphthyl, phenalenyl, aoeanthrylenyl, tetrahydronaphthyl, indanyl and biphenylyl. Of these, preferred are phenyl, naphthyl, anthracenyl and phenanthryl.
  • aryl groups may be substituted with: halogen atoms, such as fluorine, chlorine, bromine and iodine; hydrocarbon groups of 1 to 20 carbon atoms, such as alkyl groups (e.g., methyl, ethyl, propyl, butyl, hexyl, cyclohexyl, octyl, nonyl, dodecyl, icosyl, norbornyl and adamantyl), alkenyl groups (e.g., vinyl, propenyl and cyclohexenyl), arylalkyl groups (e.g., benzyl, phenylethyl and phenylpropyl) and aryl groups (e.g., phenyl, tolyl, dimethylphenyl, trimethylphenyl, ethylphenyl, propylphenyl, biphenyl, ⁇ - or ⁇ -naphthyl, methyl
  • X1 and X are each hydrogen, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, an oxygen-containing group or a sulfur-containing group.
  • Examples of the halogen atoms and the hydrocarbon groups of 1 to 20 carbon atoms are identical with those described above.
  • Examples of the halogenated hydrocarbon groups of 1 to 20 carbon atoms include those obtained by substituting the aforementioned hydrocarbon groups of 1 to 20, carbon atoms with halogen atoms.
  • oxygen-containing groups examples include hydroxyl group; alkoxy groups, such as methoxy, ethoxy, propoxy and butoxy; aryloxy groups, such as phenoxy, methylphenoxy, dimethylphenoxy and naphthoxy; and arylalkoxy groups, such as phenylmethoxy and phenylethoxy.
  • sulfur-containing groups include substituents obtained by replacing oxygen with sulfur in the above-mentioned oxygen-containing groups; sulfonato groups such as methylsulfonato, trifluoromethanesulfonato, phenylsulfonato, benzylsulfonato, p-toluenesulfonato, trimethylbenzenesulfonato, triisobutylbenzenesulfonato, p-chlorobenzenesulfonato and pentafluorobenzenesulfonato; and sulfinato groups such as methylsulfinato, phenylsulfinato, benzenesulfinato, p-toluenesulfinato, trimethylbenzenesulfinato and pentafluorobenzenesulfinato.
  • sulfonato groups such as
  • halogen atoms and hydrocarbon groups of 1 to 20 carbon atoms.
  • Y is a divalent hydrocarbon group of 1 to 20 carbon atoms, a divalent halogenated hydrocarbon group of 1 to 20 carbon atoms, a divalent silicon-containing group, a divalent germanium-containing group, -O-, -CO-, -S-, -SO-, -SO2-, NR17-, -P(R17)-, -P(O) (R17)-, -BR17- or -AlR17- (wherein R17 is hydrogen, a halogen atom, a hydrocarbon group of i to 20 carbon atoms or a halogenated hydrocarbon group of 1 to 20 carbon atoms).
  • divalent hydrocarbon groups of 1 to 20 carbon atoms examples include alkylene groups, such as methylene, dimethylmethylene, 1,2-ethylene, dimethyl-1,2-ethylene, 1,3-trimethylene, 1,4-tetramethylene, 1,2-cyclohexylene and 1,4-cyclohexylene; and arylalkylene groups, such as diphenylmethylene and diphenyl-1,2-ethylene.
  • divalent halogenated hydrocarbon groups examples include those obtained by halogenating the above-mentioned divalent hydrocarbon groups of 1 to 20 carbon atoms, such as chloromethylene.
  • divalent silicon-containing groups examples include alkylsilylene, alkylarylsilylene and arylsilylene groups, such as methylsilylene, dimethylsilylene, diethylsilylene, di(n-propyl)silylene, di(i-propyl)silylene, di(cyclohexyl)silylene, methylphenylsilylene, diphenylsilylene, di(p-tolyl)silylene and di(p-chlorophenyl)silylene; and alkyldisilyl, alkylaryldisilyl and aryldisilyl groups, such as tetramethyl-1,2-disilyl and tetraphenyl-1,2-disilyl.
  • divalent germanium-containing groups examples include those obtained by replacing silicon with germanium in the above-mentioned divalent silicon-containing groups.
  • R17 is hydrogen, or the same halogen atom, hydrocarbon group of 1 to 20 carbon atoms or halogenated hydrocarbon group of 1 to 20 carbon atoms as described above.
  • Y divalent silicon-containing groups and divalent germanium-containing groups, more preferred are divalent silicon-containing groups, and particularly preferred are alkylsilylene, alkylarylsilylene and arylsilylene.
  • transition metal compounds represented by the formula (Ia) rac-Dimethylsilylene-bis ⁇ 1-(2-methyl-4-phenylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2-methyl-4-( ⁇ -naphthyl)indenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ (1-(2-methyl-4-( ⁇ -naphthyl)indenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2-methyl-4-(1-anthracenyl)indenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2-methyl-4-(2-anthracenyl)indenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2-methyl-4-(2-anthracenyl)indenyl) ⁇
  • transition metal compounds represented by the formula (Ia) are generally used in the form of racemic modification, but they can be also used in the form of R type or S type.
  • transition metal compounds can be prepared in accordance with "Journal of Organic Chem.” 288(1985), pp. 63-67, and European Patent Publication No. 0,320,762 (specification and examples).
  • M1 is a transition metal atom of Group IVB of the periodic table, for example, titanium, zirconium or hafnium, preferably zirconium.
  • R1 and R may be the same as or different from each other, and are each hydrogen, a halogen atom, a hydrocarbon group of 1 to 20 carbon atoms, a halogenated hydrocarbon group of 1 to 20 carbon atoms, a silicon-containing group, an oxygen-containing group, a sulfur-containing group, a nitrogen-containing group or a phosphorus-containing group.
  • halogen atoms, the hydrocarbon groups of 1 to 20 carbon atoms, the halogenated hydrocarbon groups of 1 to 20 carbon atoms, the silicon-containing groups, the oxygen-containing groups and the sulfur-containing groups include those described for the formula (Ia).
  • nitrogen-containing groups examples include amino group; alkylamino groups such as methylamino, dimethylamino, diethylamino, dipropylamino, dibutylamino and dicyclohexylamino; and arylamino groups such as phenylamino, diphenylamino, ditolylamino, dinaphthylamino and methylphenylamino.
  • Examples of the phosphorus-containing groups include dimethylphosphino and diphenylphosphino.
  • R1 is preferably a hydrocarbon group, particularly preferably a hydrocarbon group of 1 to 3 carbon atoms, e.g., methyl, ethyl or propyl.
  • R is preferably hydrogen or a hydrocarbon group, particularly preferably hydrogen or a hydrocarbon group of 1 to 3 carbon atoms, e.g., methyl, ethyl or propyl.
  • R3 and R4 may be the same as or different from each other, and are each an alkyl group of 1 to 20 carbon atoms. Examples thereof include those described for the formula (Ia).
  • R3 is preferably a secondary or tertiary alkyl group.
  • R4 may contain a double bond or a triple bond.
  • X1 and X may be the same as or different from each other, and have the same meanings as defined in the formula (Ia).
  • Y has the same meaning as defined in the formula (Ia).
  • transition metal compounds represented by the formula (Ib) rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-ethylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-n-propylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-i-propylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-n-butylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-sec-butylindenyl) ⁇ zirconium dichloride, rac-Dimethylsilylene-bis ⁇ 1-(2,7-dimethyl-4-t-butylindenyl) ⁇ zirconium dichlor
  • transition metal compounds represented by the formula (Ib) are generally used in the form of racemic modification, but they can be also used in the form of R type or S type.
  • transition metal compounds represented by the formula (Ib) can be synthesized from indene derivatives by known processes, for example, a process described in Japanese Patent Laid-Open Publication No. 268307/1992.
  • M1 is a transition metal atom of Group IVB of the periodic table, for example, titanium, zirconium or hafnium, preferably zirconium.
  • Plural R31 may be the same as or different from each other, and are each hydrogen, a halogen atom (preferably chlorine or bromine), an alkyl group of 1 to 10 carbon atoms (preferably that of 1 to 4 carbon atoms), a halogenated alkyl group of 1 to 10 carbon atoms, an aryl group of 6 to 10 carbon atoms (preferably that of 6 to 8 carbon atoms), -NR302, -SR30, -OSiR303, -SiR303 or -PR303 (wherein R30 is a halogen atom (preferably chlorine), an alkyl group of 1 to 10 carbon atoms (preferably that of 1 to 3 carbon atoms), or an aryl group of 6 to 10 carbon atoms (preferably that of 6 to 8 carbon atoms)).
  • a halogen atom preferably chlorine or bromine
  • an alkyl group of 1 to 10 carbon atoms preferably that of 1 to 4 carbon atoms
  • R3 to R38 may be the same as or different from each other, and are each the same atom or group as that of R31, or at least two adjacent groups from among the groups represented by R3 to R38 may form an aromatic ring or an aliphatic ring together with atoms to which said two groups are bonded.
  • X3 and X4 may be the same as or different from each other, and are each hydrogen, an alkyl group of 1 to 10 carbon atoms (preferably that of 1 to 3 carbon atoms), an alkoxy group of 1 to 10 carbon atoms (preferably that of 1 to 3 carbon atoms), an aryl group of 6 to 10 carbon atoms (preferably that of 6 to 8 carbon atoms), an aryloxy group of 6 to 10 carbon atoms (preferably that of 6 to 8 carbon atoms), an alkenyl group of 2 to 10 carbon atoms (preferably that of 2 to 4 carbon atoms), an arylalkyl group of 7 to 40 carbon atoms (preferably that of 7 to 10 carbon atoms), an alkylaryl group of 7 to 40 carbon atoms (preferably that of 7 to 12 carbon atoms), an arylalkenyl group of 8 to 40 carbon atoms (preferably that of 8 to 12 carbon atoms), OH group or a halogen atom.
  • R39 and R40 may be the same as or different from each other, and are each hydrogen, a halogen atom, an alkyl group of 1 to 10 carbon atoms (preferably that of 1 to 4 carbon atoms, particularly preferably methyl), a fluoroalkyl group of 1 to 10 carbon atoms (preferably CF3 group), an aryl group of 6 to 10 carbon atoms (preferably that of 6 to 8 carbon atoms), a fluoroaryl group of 6 to 10 carbon atoms (preferably pentafluorophenyl), an alkoxy group of 1 to 10 carbon atoms (preferably that of 1 to 4 carbon atoms, particularly preferably methoxy), an alkenyl group of 2 to 10 carbon atoms (preferably that of 2 to 4 carbon atoms), an arylalkyl group of 7 to 40 carbon atoms (preferably that of 7 to 10 carbon atoms), an arylalkenyl group of 8 to 40 carbon atoms (preferably that of 8 to 12 carbon atoms), or an
  • R39 and R40 may form a ring together with atoms to which R39 and R40 are bonded.
  • M is silicon, germanium or tin, and is preferably silicon or germanium.
  • the alkyl group mentioned above is a straight chain or branched alkyl group; and the halogen (halogenating atom) is fluorine, chlorine, bromine or iodine, particularly fluorine or chlorine.
  • M1 is zirconium or hafnium
  • plural R31 are the same as each other, and are each an alkyl group of 1 to 4 carbon atoms
  • R3 to R38 may be the same as or different from each other, and are each hydrogen or an alkyl group of 1 to 4 carbon atoms
  • X3 and X4 may be the same as or different from each other, and are each an alkyl group of 1 to 3 carbon atoms or a halogen atom
  • Z is (wherein M is silicon, and R39 and R40 may be the same as or different from each other and are each an alkyl group of 1 to 4 carbon atoms or an aryl group of 6 to 10 carbon atoms).
  • R3 and R38 are each hydrogen, and R33 to R37 are each an alkyl group of 1 to 4 carbon atoms or hydrogen.
  • M1 is zirconium
  • plural R31 are the same as each other, and are each an alkyl group of 1 to 4 carbon atoms
  • R3 and R38 are each hydrogen
  • R33 to R37 may be the same as or different from each other, and are each an alkyl group of 1 to 4 carbon atoms or hydrogen
  • X3 and X4 are each chlorine
  • Z is (wherein M is silicon, and R39 and R40 may be the same as or different from each other and are each an alkyl group of 1 to 4 carbon atoms or an aryl group of 6 to 10 carbon atoms).
  • M1 is zirconium
  • plural R31 are each methyl
  • R3 to R38 are each hydrogen
  • X3 and X4 are each chlorine
  • Z is (wherein M is silicon, and R39 and R40 may be the same as or different from each other and are each methyl or phenyl).
  • the transition metal compounds (A') may be used in combination of two or more kinds.
  • the organoaluminum oxy-compound (B') has a molar ratio of alkyl group to aluminum atom contained therein, R/Al ratio, of not more than 1.8, preferably 1.8 to 1.2, more preferably 1.7 to 1.4.
  • the organoaluminum oxy-compound having an R/Al ratio of not more than 1.8 a commercially available aluminoxane having the above-defined R/Al ratio is employable, or the organoaluminum oxy-compound can be prepared by a process similar to that for preparing the aforesaid organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1. That is, the organoaluminum oxy-compound (B') can be prepared by the following processes:
  • organoaluminum oxy-compound having an R/Al ratio of not more than 1.8 is prepared by the above processes, the same conditions as described above in the preparation of the organoaluminum oxy-compound having an R/Al ratio of 1.7 to 2.1 can be adopted.
  • the propylene polymerization catalyst of the invention is formed from the fine particle carrier, the transition metal compound (A') and the organoaluminum oxy-compound (B'), but it may further contain the organoaluminum compound (C) if necessary.
  • the propylene polymerization catalyst may further contain other components useful for propylene polymerization in addition to the above-described components.
  • the propylene polymerization catalyst according to the invention comprises: the fine particle carrier, at least one transition metal compound (A') selected from the compounds represented by the above formulas (I), (Ia), (Ib) and (Ic), and the organoaluminum oxy-compound (B') having a molar ratio of alkyl group to aluminum atom, (alkyl group/aluminum atom), of not more than 1.8, said transition metal compound (A') and said organoaluminum oxy-compound (B') being supported on the fine particle carrier.
  • transition metal compound (A') selected from the compounds represented by the above formulas (I), (Ia), (Ib) and (Ic)
  • the organoaluminum oxy-compound (B') having a molar ratio of alkyl group to aluminum atom, (alkyl group/aluminum atom), of not more than 1.8
  • the same processes and cohditions as described above in the preparation of the olefin polymerization catalyst (solid catalyst) can be adopted.
  • the organoaluminum compound (C) may be added if necessary.
  • the propylene polymerization catalyst of the invention may be a prepolymerized catalyst obtained by prepolymerizing the solid catalyst (component) with an olefin.
  • olefins used for the prepolymerization examples include ⁇ -olefins of 2 to 30 carbon atoms, such as ethylene, propylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene and 1-tetradecene. Of these, particularly preferred is propylene or a combination of propylene and the same a-olefin as used in the polymerization.
  • the propylene polymerization catalyst of the invention is a catalyst containing the transition metal compound and the organoaluminum oxy-compound both supported on the fine particle carrier, and uses the specific transition metal compound (A') and the organoaluminum oxy-compound (B') having an R/Al ratio of not more than 1.8 in combination.
  • Such propylene polymerization catalyst shows high polymerization activity and hardly produces a low-molecular component. Further, the propylene polymer obtained by the use of such catalyst shows excellent particle properties and does not stick to the wall of the polymerization reactor.
  • homopolymerization of propylene or copolymerization of propylene and other olefin than propylene is carried out in the presence of the above-mentioned propylene polymerization catalyst so as to prepare a propylene polymer.
  • the propylene polymer means a (co)polymer having a ratio of the propylene units to the whole monomer units in the (co) polymer of not less than 50 % by mol, and includes a homopolymer of propylene and a random or block copolymer of propylene and other olefin than propylene.
  • olefins to be copolymerized with propylene examples include ⁇ -olefins of 2 to 20 carbon atoms other than propylene and cycloolefins of 5 to 20 carbon atoms. Also employable are styrene, vinylcyclohexane and diene.
  • the polymerization can be carried out by any of a liquid phase polymerization process and a gas phase polymerization process.
  • a liquid phase polymerization process the same inert hydrocarbon solvent as used for preparing the catalyst is employable, or the olefin itself can be also used as the solvent.
  • the same conditions as described above in the (co)polymerization of an olefin using the olefin polymerization catalyst can be adopted.
  • an organoaluminum compound identical with the organoaluminum compound (C) may be used in the polymerization, and in this case, the organoaluminum compound is used in an amount of not more than 500 mol, preferably 5 to 200 mol, per 1 g ⁇ atom of the transition metal atom in the transition metal compound (A').
  • olefin polymerization catalyst of the invention By the use of the olefin polymerization catalyst of the invention, a fine-powdery polymer is hardly produced in the polymerization procedure, and a polymer showing excellent particle properties can be obtained.
  • a fine-powdery polymer is hardly produced in the polymerization procedure, and a polymer showing excellent particle properties can be obtained. Moreover, the resulting olefin polymer does not stick to the wall of the polymerization reactor.
  • the propylene polymerization catalyst of the invention has high polymerization activity and hardly produces a low-molecular component. Moreover, the resulting propylene polymer shows excellent particle properties, and the propylene polymer does not stick to the wall of the polymerization reactor.
  • a propylene polymer showing excellent particle properties can be prepared with high polymerization activity, and a low-molecular component is hardly produced. Moreover, the resulting propylene polymer does not stick to the wall of the polymerization reactor.
  • the system was cooled to 0 °C, and 1.8 g of silica containing 0.26 g of water was dropwise added over a period of 30 minutes, while keeping the temperature of the system at 0 to 2 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 30 minutes, and the reaction was carried out at the same temperature for 6 hours. Then, the system was cooled to room temperature, and the supernatant liquid was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 2.00 and TMA (Area) of 0.32.
  • the prepolymerized catalyst (b-1) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-1) had a favorable shape, a bulk density of 0.40 g/cm3 and a fluidity index of 55.
  • An electron photomicrograph of the particle structure of the prepolymerized catalyst (b-1) is shown in Fig. 4.
  • the polymer produced was recovered by filtration and dried overnight at 80 °C, to obtain 346 g of an ethylene-1-hexene copolymer having a melt flow rate (MFR), as measured at 190 °C under a load of 2.16 kg, of 0.15 g/10 min, a density of 0.924 g/cm3, a bulk density of 0.45 g/cm3 and a mean particle diameter of 600 ⁇ m.
  • MFR melt flow rate
  • a solid catalyst (a-2) was prepared in the same manner as in Example 1 except that methylaluminoxane having a CH3/Al molar ratio of 2.23 and TMA (Area) of 0.42 was used in place of the methylaluminoxane having a CH3/Al molar ratio of 2.00.
  • TMA Readenum-Al molar ratio of 2.23
  • TMA Readenum-Al molar ratio of 0.42
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except that 0.005 mmol (in terms of zirconium) of the prepolymerized catalyst (b-2) was used in place of the prepolymerized catalyst (b-1), to obtain 304 g of an ethylene-1-hexene copolymer having MFR of 0.17 g/10 min, a density of 0.925 g/cm3, a bulk density of 0.44 g/cm3 and a mean particle diameter of 540 ⁇ m.
  • the system was cooled to 0 °C, and 3.0 g of silica containing 0.65 g of water was dropwise added over a period of 45 minutes, while keeping the temperature of the system at 0 to 2 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 30 minutes, and the reaction was carried out at the same temperature for 6 hours. Then, the system was cooled to room temperature, and the supernatant was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 1.69 and TMA (Area) of 0.24.
  • a solid catalyst (a-3) was prepared in the same manner as in Example 1 except that the methylaluminoxane having a CH3/Al molar ratio of 1.69 as obtained above was used in place of the methylaluminoxane having a CH3/Al molar ratio of 2.00 as prepared in Example 1.
  • a-3 143 mg of aluminum and 3.6 mg of zirconium were contained.
  • the prepolymerized catalyst (b-3) did not stick to the reactor or, the stirring blade.
  • the prepolymerized catalyst (b-3) had an unfavorable shape, a bulk density of 0.31 g/cm3 and a fluidity index of 44.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except that 0.005 mmol (in terms of zirconium) of the prepolymerized catalyst (b-3) was used in place of the prepolymerized catalyst (b-1), to obtain 272 g of an ethylene-1-hexene copolymer having MFR of 0.14 g/10 min, a density of 0.924 g/cm3, a bulk density of 0.40 g/cm3 and a mean particle diameter of 470 ⁇ m.
  • the system was cooled to 0 °C, and 1.7 g of silica containing 0.15 g of water was dropwise added over a period of, 30 minutes, while keeping the temperature of the system at 0 to 2 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 30 minutes, and the reaction was carried out at the same temperature for 6 hours. Then, the system was cooled to room temperature, and the supernatant was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 2.03 and TMA (Area) of 0.37.
  • a solid catalyst (a-4) was prepared in the same manner as in Example 1 except that the methylaluminoxane having a CH3/Al molar ratio of 2.03 as obtained above was used in place of the methylaluminoxane having a CH3/Al molar ratio of 2.00 as prepared in Example 1.
  • the solid catalyst (a-4) 140 mg of aluminum and 3.5 mg of zirconium were contained.
  • the prepolymerized catalyst (b-4) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-4) had a favorable shape, a bulk density of 0.39 g/cm3 and a fluidity index of 53.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except that 0.005 mmol (in terms of zirconium) of the prepolymerized catalyst (b-4) was used in place of the prepolymerized catalyst (b-1), to obtain 362 g of an ethylene-1-hexene copolymer having MFR of 0.13 g/10 min, a density of 0.925 g/cm3, a bulk density of 0.44 g/cm3 and a mean particle diameter of 640 ⁇ m.
  • the system was cooled to 0 °C, and 1.7 g of silica containing 0.16 g of water was dropwise added over a period of, 30 minutes, while keeping the temperature of the system at 0 to 2 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 30 minutes, and the reaction was carried out at the same temperature for 6 hours. Then, the system was cooled to room temperature, and the supernatant was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 1.97 and TMA (Area) of 0.35.
  • a solid catalyst (a-5) was prepared in the same manner as in Example 1 except that the methylaluminoxane having a CH3/Al molar ratio of 1.97 as obtained above was used in place of the methylaluminoxane having a CH3/Al molar ratio of 2.00 as prepared in Example 1.
  • a-5 137 mg of aluminum and 3.6 mg of zirconium were contained.
  • the prepolymerized catalyst (b-5) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-5) had a favorable shape, a bulk density of 0.39 g/cm3 and a fluidity index of 53.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except that 0.005 mmol (in terms of zirconium) of the prepolymerized catalyst (b-5) was used in place of the prepolymerized catalyst (b-1), to obtain 346 g of an ethylene-1-hexene copolymer having MFR of 0.16 g/10 min, a density of 0.924 g/cm3, a bulk density of 0.44 g/cm3 and a mean particle diameter of 610 ⁇ m.
  • the system was cooled to 0 °C. Then, 2.4 g of silica having an adsorbed water content of 0.005 % by weight and a surface hydroxyl group content of 3.0 % by weight was dropwise added over a period of 30 minutes, while keeping the temperature of the system at 0 to 2 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 30 minutes, and the reaction was carried out for 6 hours at the same temperature. Then, the system was cooled to room temperature, and the supernatant was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 1.72 and TMA (Area) of 0.32.
  • a solid catalyst (a-6) was prepared in the same manner as in Example 1 except that the methylaluminoxane having a CH3/Al molar ratio of 1.72 as obtained above was used in place of the methylaluminoxane having a CH3/Al molar ratio of 2.00 as prepared in Example 1.
  • a-6 138 mg of aluminum and 3.4 mg of zirconium were contained.
  • the prepolymerized catalyst (b-6) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-6) had a favorable shape, a bulk density of 0.39 g/cm3 and a fluidity index of 53.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except that 0.005 mmol (in terms of zirconium) of the prepolymerized catalyst (b-6) was used in place of the prepolymerized catalyst (b-1), to obtain 357 g of an ethylene-1-hexene copolymer having MFR of 0.15 g/10 min, a density of 0.925 g/cm3, a bulk density of 0.44 g/cm3 and a mean particle diameter of 620 ⁇ m.
  • a prepolymerized catalyst (bb-7) was prepared in the same manner as in Example 1 except that bis(1,3-n-propylmethylcyclopentadienyl)zirconium dichloride was used in place of bis(1,3-n-butylmethylcyclopentadienyl)zirconium dichloride for obtaining a solid catalyst (aa-7).
  • the prepolymerized catalyst (bb-7) contained 3.2 mg of zirconium and 3 g of a polymer per 1 g of the solid catalyst (aa-7), and had a bulk density of 0.39 g/cm3 and a fluidity index of 51.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except for using the prepolymerized catalyst (bb-7), to obtain 363 g of an ethylene-1-hexene copolymer having MFR of 0.17 g/10 min, a density of 0.926 g/cm3, a bulk density of 0.43 g/cm3 and a mean particle diameter of 650 ⁇ m.
  • a prepolymerized catalyst (bb-8) was prepared in the same manner as in Example 5 except for using bis(1,3-dimethylcyclopentadienyl)zirconium dichloride for obtaining a solid catalyst (aa-8).
  • the propolymerized catalyst (bb-8) contained 3.1 mg of zirconium and 3 g of a polymer per 1 g of the solid catalyst (aa-8), and had a bulk density of 0.37 g/cm3 and a fluidity index of 47.
  • Polymerization of ethylene and 1-hexene was carried out in the same manner as in Example 1 except for using the prepolymerized catalyst (bb-8), to obtain 313 g of an ethylene-1-hexene copolymer having MFR of 0.01 g/10 min or less, a density of 0.923 g/cm3, a bulk density of 0.40 g/cm3 and a mean particle diameter of 650 ⁇ m.
  • the system was cooled to 0 °C, and 775 g of silica containing 140 g of water was dropwise added over a period of 65 minutes, while keeping the temperature of the system at 0 to 5 °C. After the dropwise addition was completed, the reaction was carried out at 0 °C for 30 minutes.
  • the temperature of the system was raised to 40 °C over a period of 1 hour, and the reaction was carried out at the same temperature for 6 hours. Then, the system was cooled to room temperature, and the supernatant was recovered.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution, and the methylaluminoxane had a CH3/Al molar ratio of 2.00 and TMA (Area) of 0.32.
  • the solid component thus obtained was washed twice with toluene and resuspended in 80 liters of toluene.
  • To the system was dropwise added 8.6 liters of a toluene solution of bis(1,3-n-butylmethylcyclopentadienyl)zirconium dichloride (Zr: 29.9 mmol/liter) at 80 °C over a period of 30 minutes, and the reaction was carried out at 80 °C for 2 hours. Then, the supernatant was removed and the remainder was washed twice with hexane, to obtain a solid catalyst (a-7) containing 3.6 mg of zirconium per 1 g of the solid catalyst.
  • polymerization conditions were varied as shown in Table 2 to synthesize ethylene-1-hexene copolymers different in MFR and density. In each process, the polymerization proceeded very stably, and it was found that no polymer stuck to the wall of the reactor even after one-week continuous operation.
  • silica specific surface area: 321 m/g, mean particle diameter: 54 ⁇ m
  • the temperature was raised to 60 °C to perform reaction for 2 hours.
  • the supernatant was removed, and the remainder was washed twice with hexane to obtain a solid catalyst (a-8) containing 3.2 mg, of zirconium per 1 g of the solid catalyst.
  • the prepolymerized catalyst (b-8) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-8) had a favorable shape, a bulk density of 0.37 g/cm3 and a fluidity index of 46.
  • the polymer produced was recovered by filtration and dried overnight at 80 °C, to obtain 387 g of an ethylene-1-hexene copolymer. In this procedure, it was found that no polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • the ethylene-1-hexene copolymer thus obtained had an MFR, as measured at 190 °C under a load of 2.16 kg, of 0.16 g/10 min, a density of 0.925 g/cm3, a bulk density of 0.35 g/cm3 and a mean particle diameter of 740 ⁇ m.
  • a prepolymerized catalyst (b-9) was prepared in the same manner as in the procedure of "preparation of catalyst" in Example 8 except that a methylaluminoxane having a CH3/Al molar ratio of 1.63 was used in place of the methylaluminoxane having a CH3/Al molar ratio of 1.69.
  • the prepolymerized catalyst (b-9) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-9) had a favorable shape, a bulk density of 0.36 g/cm3 and a fluidity index of 45.
  • An ethylene-1-hexene copolymer was prepared in the same manner as in the procedure of "polymerization" in Example 8 except that the prepolymerized catalyst (b-9) was used in place of the prepolymerized catalyst (b-8). In this procedure, it was found that no polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • a prepolymerized catalyst (b-10) was prepared in the same manner as in the procedure of "preparation of catalyst" in Example 8 except that a methylaluminoxane having a CH3/Al molar ratio of 1.57 was used in place of the methylaluminoxane having a CH3/Al molar ratio of 1.69.
  • the prepolymerized catalyst (b-10) did not stick to the reactor or the stirring blade.
  • the prepolymerized catalyst (b-10) had a favorable shape, a bulk density of 0.36 g/cm3 and a fluidity index of 46.
  • An ethylene-1-hexene copolymer was prepared in the same manner as in the procedure of "polymerization" in Example 8 except that the prepolymerized catalyst (b-10) was used in place of the prepolymerized catalyst (b-8). In this procedure, it was found that no polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • Liquid components in the flask were completely distilled off under the conditions of a temperature in the flask of 37 to 40 °C, a constant distillate temperature of 27 to 28.5 °C, a pressure of 30 mmHg and a period of 4 hours, remaining 53.6 g of a dried white methylaluminoxane in the flask, to which 650 ml of toluene was added to redissolve the methylaluminoxane.
  • the toluene solution of methylaluminoxane thus obtained was a colorless transparent homogeneous solution having an Al concentration of 1.32 mol/liter, and the methylaluminoxane had a CH3/Al molar ratio of 1.54.
  • a propylene gas (1.6 l/hr) was passed through the reactor at 20 °C for 2 hours to perform prepolymerization of propylene.
  • the supernatant was removed by decantation, and the remainder was washed three times with 150 ml of hexane and resuspended in n-decane.
  • a prepolymerized catalyst (b-11) containing 3 g of polypropylene, 0.0096 mmol of zirconium and 4.78 mmol of aluminum per 1 g of the solid component (c-1) was obtained.
  • the prepolymerized catalyst (b-11) did not stick to the reactor or the stirring blade, and the prepolymerized catalyst (b-11) had a favorable shape.
  • a propylene gas (1.6 l/hr) was passed through the reactor at 20 °C for 2 hours to perform prepolymerization of propylene.
  • the supernatant was removed by decantation, and the remainder was washed three times with 150 ml of hexane and resuspended in n-decane.
  • a prepolymerized catalyst (b-13) containing 3 g of polypropylene, 0.0094 mmol of zirconium and 4.82 mmol of aluminum per 1 g of the solid component (c-1) was obtained. In the above procedure, it was found that the prepolymerized catalyst (b-13) did not stick to the reactor or the stirring blade.
  • 143 g of a polymer was obtained, and the polymerization activity was 2,700 g/g-catalyst and 286 kg-polymer/mmol-Zr ⁇ hr.
  • This polymer had a content of n-decane-soluble component of 0.48 % by weight, MFR of 2.0 g/10 min, a melting point of 129 °C and a bulk density of 0.42 g/cm3. It was found that no polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • a solid component (c-2) containing 6.2 mmol of aluminum per 1 g of silica was prepared in the same manner as in Example 11 except that a toluene solution of methylaluminoxane having a CH3/Al molar ratio of 1.57 (Al: 1.41 mol/liter) was used in place of the toluene solution of methylaluminoxane having a CH3/Al molar ratio of 1.54.
  • a prepolymerized catalyst (b-14) was obtained in the same manner as in Example 11 except that the solid component (c-2) was used in place of the solid component (c-1).
  • the prepolymerized catalyst (b-14) contained 3 g of polypropylene, 0.0116 mmol of zirconium and 4.65 mmol of aluminum per 1 g of the solid component (c-2).
  • 160.2 g of a polymer was obtained, and the polymerization activity was 1,900 g/g-catalyst and 160.2 kg-polymer/mmol-Zr ⁇ hr.
  • This polymer had a content of n-decane-soluble component of 0.55 % by weight, MFR of 0.21 g/10 min, a melting point of 150 °C and a bulk density of 0.40 g/cm3. It was found that no polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • a solid component (c-3) containing 5.8 mmol of aluminum per 1 g of silica was prepared in the same manner as in Example 11 except that a toluene solution of methylaluminoxane having a CH3/Al molar ratio of 1.69 (Al: 1.45 mol/liter) was used in place of the toluene solution of methylaluminoxane having a CH3/Al molar ratio of 1.54.
  • a prepolymerized catalyst (b-15) was obtained in the same manner as in Example 11 except that the solid component (c-3) was used in place of the solid component (c-1).
  • the prepolymerized catalyst (b-15) contained 3 g of polypropylene, 0.0124 mmol of zirconium and 4.85 mmol of aluminum per 1 g of the solid component (c-3).
  • a solid component (c-4) containing 6.1 mmol of aluminum per 1 g of silica was prepared in the same manner as in Example 11 except that a toluene solution of methylaluminoxane having a CH3/Al molar ratio of 2.12 was used in place of the toluene solution of methylaluminoxane having a CH3/Al molar ratio of 1.54.
  • a prepolymerized catalyst (b-16) was obtained in the same manner as in Example 11 except that the solid component (c-4) was used in place of the solid component
  • the prepolymerized catalyst (b-16) contained 3 g of polypropylene, 0.0143 mmol of zirconium and 5.38 mmol of aluminum per 1 g of the solid component (c-4).
  • Copolymerization of propylene and ethylene was carried out in the same manner as in Example 12 except that the prepolymerized catalyst (b-16) was used in place of the prepolymerized catalyst (b-11).
  • the polymerization activity was 900 g/g-catalyst and 52 kg-polymer/mmol-Zr ⁇ hr.
  • This polymer had a content of n-decane-soluble component of 5.94 % by weight, MFR of 1.05 g/10 min, a melting point of 131 °C and a bulk density of 0.35 g/cm3. It was found that the polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • a prepolymerized catalyst (b-17) was obtained in the same manner as in Example 13 except that the solid component (c-4) as prepared in Comparative Example 3 was used in place of the solid component (c-1) .
  • the prepolymerized catalyst (b-17) contained 3 g of polypropylene, 0.0109 mmol of zirconium and 4.08 mmol of aluminum per 1 g of the soloid component (c-4).
  • Copolymerization of propylene and ethylene was carried out in the same manner as in Example 13 except that 0.001 mmol (in terms of zirconium) of the prepolymerized catalyst (b-17) was used in place of the prepolymerized catalyst (b-12).
  • 73 g of a polymer was obtained, and the polymerization activity was 730 g/g-catalyst and 73 kg-polymer/mmol-Zr ⁇ hr.
  • This polymer had a content of n-decane-soluble component of 4.5 % by weight, MFR of 3.00 g/10 min, a melting point of 132 °C and a bulk density of 0.36 g/cm3. It was found that the polymer stuck to the wall of the polymerization reactor or the stirring blade.
  • a prepolymerized catalyst (b-18) was obtained in the same manner as in Example 14 except that the solid component (c-4) prepared in Comparative Example 3 was used in place of the solid component (c-1).
  • the prepolymeized catalyst (b-18) contained 3 g of polypropylene, 0.0102 mmol of zirconium and 4.25 mmol of aluminum per 1 g of the solid component (c-4).
  • Copolymerization of propylene and ethylene was carried out in the same manner as in Example 14 except that the prepolymerized catalyst (b-18) was used in place of the prepolymerized catalyst (b-13).
  • a propylene gas (1.6 l/hr) was passed through the reactor at 20 °C for 2 hours to perform prepolymerization of propylene.
  • the supernatant was removed by decantation, and the remainder was washed three times with 150 ml of hexane and resuspended in n-decane.
  • a prepolymerized catalyst (b-19) containing 3 g of. polypropylene, 0.0109 mmol of zirconium and 4.80 mmol of aluminum per 1 g of the solid component (c-1) was obtained.
  • the prepolymerized catalyst (b-13) did not stick to the reactor or the stirring blade.
  • a prepolymerized catalyst (b-20) was obtained in the same manner as in Example 17 except that the solid component (c-4) was used in place of the solid component (c-1).
  • the prepolymerized catalyst (b-20) contained 3 g of polypropylene, 0.0110 mmol of zirconium and 4.86 mmol of aluminum per 1 g of the solid component (c-4).

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EP95305560A 1994-08-09 1995-08-09 Catalyseur de polymérisation d'oléfines et procédé de polymérisation d'oléfines Expired - Lifetime EP0697419B2 (fr)

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JP5695419B2 (ja) * 2007-08-29 2015-04-08 アルベマール・コーポレーシヨン ジアルキルアルミニウム陽イオンの前駆剤から生じるアルミノキサン触媒活性剤、同物質の製造方法、ならびにオレフィンの触媒および重合におけるその用途
BRPI0920222A2 (pt) * 2008-10-03 2019-09-24 Univation Tech Llc composições catalisadoras e métodos de produção e uso das mesmas
SG190429A1 (en) 2010-11-30 2013-06-28 Univation Tech Llc Catalyst composition having improved flow characteristics and methods of making and using the same
EP2663400A4 (fr) 2011-01-14 2014-07-30 Grace W R & Co Procédé de préparation d'un catalyseur métallocène modifié, catalyseur ainsi produit et son utilisation
ES2768180T3 (es) 2013-01-30 2020-06-22 Univation Tech Llc Procedimientos para producir composiciones catalíticas con fluidez mejorada
JP6360682B2 (ja) * 2014-02-26 2018-07-18 三井化学株式会社 オレフィン重合に用いる予備重合触媒成分の製造方法および当該予備重合触媒成分を用いたオレフィン重合体の製造方法
KR102278013B1 (ko) * 2017-12-21 2021-07-15 주식회사 엘지화학 폴리프로필렌 부직포 제조 방법
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EP0650967A1 (fr) * 1993-10-27 1995-05-03 Witco GmbH Procédé de préparation d'alkylaluminoxanes sur support inerte

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998022477A1 (fr) * 1996-11-22 1998-05-28 Boulder Scientific Company Preparation de titanocenes chiraux
WO1998040416A1 (fr) * 1997-03-07 1998-09-17 Targor Gmbh Systeme de catalyseur sur support, procede permettant de le produire et son utilisation pour la polymerisation d'olefines
US6444606B1 (en) 1997-03-07 2002-09-03 Basell Polypropylen Gmbh Supported catalyst system, method for the production and use thereof in olefin polymerization
EP1026177A1 (fr) * 1997-10-22 2000-08-09 Chisso Corporation Catalyste metallocene supporte, procede pour sa preparation et procede pour la production de polymeres olefines
EP1026177A4 (fr) * 1997-10-22 2004-12-08 Chisso Corp Catalyste metallocene supporte, procede pour sa preparation et procede pour la production de polymeres olefines

Also Published As

Publication number Publication date
KR960007626A (ko) 1996-03-22
EP0697419B2 (fr) 2004-12-01
KR0172607B1 (ko) 1999-03-30
US6043325A (en) 2000-03-28
CA2155621C (fr) 2000-05-09
TW454020B (en) 2001-09-11
CA2155621A1 (fr) 1996-02-10
CN1048990C (zh) 2000-02-02
DE69509458D1 (de) 1999-06-10
EP0697419B1 (fr) 1999-05-06
US5795838A (en) 1998-08-18
DE69509458T2 (de) 1999-09-02
DE69509458T3 (de) 2005-06-23
CN1121079A (zh) 1996-04-24

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